Counter flow mixer for process chamber

ABSTRACT

A counterflow mixing device for a process chamber is disclosed, comprising an injection tube that introduces a fluid in a manner counter to a flow of a post-plasma gas mixture traveling downward from a plasma source. The invention allows for proper mixing of the fluid as well as avoiding recombination of generated ions and radicals.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 62/253,016, which was filed on Nov. 9, 2015 and is incorporated herein by reference.

FIELD OF INVENTION

The present disclosure generally relates to semiconductor processing tools. More particularly, the disclosure relates to a low pressure mixer of gas travelling from a small flow tube into a large flow tube.

BACKGROUND OF THE DISCLOSURE

Certain cleaning or other low vacuum processes require the mixing of a gas/vapor between a plasma source (PS) and the wafer processing chamber. For example, a NF₃/NH₃ process can be used to remove SiO₂ from Si. In this process, Ar is mixed with NF₃ prior to being injected into a top PS.

Plasma is produced in the PS, which, in addition to some ionization of the Ar/NF₃ mix, produces Fluorine radicals that are highly reactive. A relatively large diameter (˜25 mm to 50 mm diameter) with a relatively short length (˜100 mm to 300 mm) conductance tube is used between the PS and the chamber in order to minimize recombination of the Fluorine radicals.

In the example process, NH₃ cannot be mixed with the Ar/NF₃ prior to the PS because disassociation of the NH₃ is undesirable. The NH₃ is typically injected into a side of the PS to chamber conductance tube. However, injection into the side of conductance tube that has a low length to diameter ratio (˜2:1 to 12:1) will not provide effective mixing and thus, will lead to an uneven distribution of the NH₃ on the wafer being processed. Uniformity of the distribution of the NH₃ over the wafer is required for a robust and repeatable process.

Issues arising in the example process are attributable in part to: (1) insufficient diffusion time to ensure complete mixing; and (2) preservation of streamlines at required pressures. Mixing time is a function of a length and a diameter of a tube in which the gases flow viscously at a given velocity. To achieve complete mixing the tube must be long enough so that the time of the viscous flow from inlet to outlet exceeds the time for diffusion across the diameter. Generally, the tube length to tube diameter ratio may exceed 20:1 to achieve complete mixing. However, given the fact that the diameter must be large to preserve the formed F radicals, a 20:1 length to diameter ratio may not be feasible.

Streamlines are capable of affecting mixing of gases. At particular pressures, if streamlines of a flowing gas remain undisturbed, a flow of introduced gases may not be able to be properly mixed. For example, pressures resulting from gases leaving the PS range between 1 to 10 Torr. At these pressures, the flow of gases is generally laminar.

As a result, it is desired to create a system in which a gas is sufficiently mixed as well as minimization of radical/ion recombination from a plasma source.

SUMMARY OF THE DISCLOSURE

In accordance with at least one embodiment of the invention, an apparatus is disclosed that comprises in part a plasma source, a conical member, a counterflow injector, and a configurable orifice plate. The conical member is configured to receive a first gas in a first direction and promotes a mixing of the first gas and the second gas. The counter flow injector introduces a second gas in a second direction, such that the first direction is opposite to the second direction. The apparatus includes a configurable orifice plate mounted at the bottom of the conical member, the adjustable orifice plate defining an opening through which the first gas and the second gas pass through, such that changing a size of the opening of the configurable orifice plate changes an extent of the mixing of the first gas and the second gas.

In accordance with at least one embodiment of the invention, a reaction system is disclosed. The reaction system comprises: a plasma source, the plasma source generating a first gas; a conical member, the conical member configured to receive the first gas in a first direction; a counter flow injector, the counter flow injector introducing a second gas in a second direction, wherein the first direction is opposite to the second direction; an adjustable orifice plate mounted at the bottom of the conical member, the adjustable orifice plate defining an opening through which the plasma gas and the first fluid pass through; a reaction chamber that receives the first gas and the second gas, the reaction chamber comprising: a housing defining a plenum to receive the first gas and the second gas; and a showerhead with a plurality of holes for passing the first gas and the second gas onto a substrate to be processed; wherein the conical member promotes a mixing of the first gas and the second gas; and wherein adjusting a size of the opening of the adjustable orifice plate changes an extent of the mixing of the first gas and the second gas.

For purposes of summarizing the invention and the advantages achieved over the prior art, certain objects and advantages of the invention have been described herein above. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught or suggested herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments will become readily apparent to those skilled in the art from the following detailed description of certain embodiments having reference to the attached figures, the invention not being limited to any particular embodiment(s) disclosed.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

These and other features, aspects, and advantages of the invention disclosed herein are described below with reference to the drawings of certain embodiments, which are intended to illustrate and not to limit the invention.

FIG. 1 is a cross-sectional view of a reaction system in accordance with at least one embodiment of the invention.

FIG. 2 is a cross-sectional view of a reaction system in accordance with at least one embodiment of the invention.

FIG. 3 is a top perspective view of a component of the reaction system in accordance with at least one embodiment of the invention.

FIG. 4 is a top perspective view of a component of the reaction system in accordance with at least one embodiment of the invention.

FIG. 5 is a bottom perspective view of a component of the reaction system in accordance with at least one embodiment of the invention.

FIG. 6 is a perspective view of a component of the reaction system in accordance with at least one embodiment of the invention.

It will be appreciated that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of illustrated embodiments of the present disclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Although certain embodiments and examples are disclosed below, it will be understood by those in the art that the invention extends beyond the specifically disclosed embodiments and/or uses of the invention and obvious modifications and equivalents thereof. Thus, it is intended that the scope of the invention disclosed should not be limited by the particular disclosed embodiments described below.

FIG. 1 illustrates a cross-sectional view of a reaction system 100 in accordance with at least one embodiment of the invention. The reaction system 100 comprises a plasma source. The plasma source (“PS”, illustrated as “Plasma Gas Source” in FIG. 1) generates a first gas 110 from a gaseous mixture using RF energy to excite gas. For example, the plasma source may receive a mixture of Argon and NF₃, WF₆, or other fluorine containing gas. The plasma source may partially ionize the gaseous mixture to form a glow discharge plasma and in the process form F radicals that are highly chemically reactive. Examples of PSs include the ASTRON® Paragon from MKS Instruments, Inc. and the Litmas from Advanced Energy Industries, Inc. Plasma sources may also be custom designed and built for the application.

The first gas 110 flows and passes through a seal 120 to a conical funnel portion 130. In one embodiment of the invention, the seal 120 may have a diameter of 50 mm. The conical funnel portion 130 is made of suitable material such as: aluminum; anodized aluminum; plasma electrolytic oxide (PEO) coated aluminum; alumina; aluminum nitride; silicon carbide; nickel; nickel plated aluminum; or nickel-plated stainless steel, for example. The conical funnel portion 130 may include a hole in which a counter flow injector 140 is disposed. The counter flow injector 140 comprises a small injection tube that turns upward toward the PS. The counter flow injector 140 may be made of suitable material such as nickel or nickel-plated stainless steel. Other materials that may be used include: anodized aluminum base material; PEO coated aluminum base material; ALD Al₂O₃ coated aluminum base material; aluminum oxide ceramic; aluminum nitride ceramic; or silicon carbide, for example.

The counter flow injector 140 introduces a second gas 150 that flows counter to the first gas 110 flowing down from PS. The fluid introduced through the counter flow injector 140 will flow upwards into the gas flowing down from the PS until the first gas 110 causes the second gas 150 to flow back downwards. When the fluid turns back, a streamline from the counter flow injector 140 is not preserved and in essence, mixture of the injected fluid into the plasma gas takes place.

The second gas 150 is first generated by an injector gas source 160. The injector gas source 160 may provide ammonia (NH₃), amines, or hydrogen (H₂), for example. For example, NH₃ gas may flow through the counter flow injector 140 and mix with the Argon and NF₃ post-plasma mixture. From the injector gas source 160, the second gas 150 then passes through a set of valves 170. The set of valves 170 may be valves manufactured by Swagelok Co., for example.

The counter flow injector 140 also does not provide a significant blockage of a main tube defined in part by the seal 120. By not providing a significant blockage of the main tube, recombination of the F radicals can be minimized within the gas mixture and on the walls.

In an alternative embodiment of the invention, a plate 180 may be placed above the counter flow injector 140 to enhance the spread of the second gas 150 radially. As illustrated in FIG. 3, the plate 180 may be supported by three thin radial arms 190 to minimize the flow disruption. The plate 180 also shields the counter flow injector 140 from fluorine radicals that would otherwise recombine and heat the counter flow injector 140 beyond the maximum allowable temperature of the part. The plate 180 and the radial arms 190 may be made from a high temperature capable and high thermal conductivity material such as aluminum nitride or silicon carbide. This allows use of more easily fabricated materials such as stainless steel and aluminum for the counter flow injector 140 that do not have sufficient temperature capability to withstand the fluorine recombination on the surface.

The gas mixture then proceeds through a configurable orifice plate 200. By changing the size of the orifice, the configurable orifice plate 200 can change a mixing time of the gas mixture. A greater orifice size of the configurable orifice plate 200 may allow the gas mixture to flow downwards slower compared to a smaller orifice size. The orifice can also be changed to influence residence time above the orifice to control the completeness of a gas phase reaction. In an embodiment where the seal 120 has a diameter of 50 mm, the configurable orifice plate 180 may have a diameter of 9 mm.

A faster rate of travel means that the gas mixture has lesser residence time in the conical funnel portion 130, and thus, the injected fluid may not be as well mixed as a gas mixture that has a greater residence time in the conical funnel portion 130. However, the increased residence time could potentially cause an issue as it may allow for the recombination of generated radicals. As a result, the size of the configurable orifice plate 200 may need to be adjusted accordingly.

After passing the configurable orifice plate 200, the gas mixture would travel into a lower tube 210, where then it would enter into a reaction system 220 having a defined plenum 230.

Within the plenum 230, the gas mixture may spread out along a showerhead plate 240. The showerhead plate 240 serves the purpose of distributing the gas mixture evenly along a substrate (not pictured). The showerhead plate 240 comprises a plurality of injection holes 250.

FIG. 2 provides a zoomed-in view of an upper section of FIG. 1. The flow of the first gas 110 is to counter the second gas 150 in accordance with at least one embodiment of the invention. The second gas 150 may be able to spread out through a space defined by the seal 120 in order to allow for sufficient mixing of the injected fluid with the first gas 110. The combined gas mixture would then flow in a direction defined by arrows 260 into the configurable orifice plate 200 and the lower tube 210.

FIGS. 4-5 illustrate a top view and a bottom view of the conical funnel portion 130 and the counter flow injector 140 in accordance with at least one embodiment of the invention. The conical funnel portion 130 may include a top portion 270 that mounts to a portion of the plasma source. The conical funnel portion 130 may also include a bottom portion 280 that interfaces with the configurable orifice plate 200. Connected to the counter flow injector 140 is a portion of the set of valves 170.

FIG. 6 is a perspective view of the configurable orifice plate 200 in accordance with at least one embodiment of the invention. The configurable orifice plate 200 defines an opening 290 in which the gas mixture is allowed to pass through to the lower tube 210. The size of the opening 290 may be adjusted by switching to a different configurable orifice plate 200, which then may affect the flow velocity of the gas mixture 260 as well as the residence time of the gas mixture 260. If the size of the opening 290 is larger, a lower flow velocity of the gas mixture may result in a higher residence time, as well as greater mixing of the introduced fluid 150 into the plasma gas 110. On the other hand, if the size of the opening 290 is smaller, a greater flow velocity of the gas mixture 260 may result in a smaller residence time, as well as less mixing of the introduced fluid 150 into the plasma gas 110.

The particular implementations shown and described are illustrative of the invention and its best mode and are not intended to otherwise limit the scope of the aspects and implementations in any way. Indeed, for the sake of brevity, conventional manufacturing, connection, preparation, and other functional aspects of the system may not be described in detail. Furthermore, the connecting lines shown in the various figures are intended to represent exemplary functional relationships and/or physical couplings between the various elements. Many alternative or additional functional relationship or physical connections may be present in the practical system, and/or may be absent in some embodiments.

It is to be understood that the configurations and/or approaches described herein are exemplary in nature, and that these specific embodiments or examples are not to be considered in a limiting sense, because numerous variations are possible. The specific routines or methods described herein may represent one or more of any number of processing strategies. Thus, the various acts illustrated may be performed in the sequence illustrated, in other sequences, or omitted in some cases.

The subject matter of the present disclosure includes all novel and nonobvious combinations and subcombinations of the various processes, systems, and configurations, and other features, functions, acts, and/or properties disclosed herein, as well as any and all equivalents thereof. 

We claim:
 1. An apparatus for mixing at least one gas, comprising: a conical member comprising a top end and a bottom end, the conical member configured to receive a first gas in a first direction at the top end; a counter flow injector disposed within the conical member, the counter flow injector introducing a second gas in a second direction, wherein the first direction is opposite to the second direction; a configurable orifice plate mounted at the bottom of the conical member, the configurable orifice plate defining an opening through which the first gas and the second gas pass through; wherein the conical member promotes a mixing of the first gas and the second gas between the top end and the bottom end; and wherein changing a size of the opening of the configurable orifice plate changes an extent of the mixing of the first gas and the second gas.
 2. The apparatus of claim 1, wherein the first gas and the second gas pass on into a reactor system having a plenum and a showerhead.
 3. The apparatus of claim 1, wherein the first gas comprises at least one of: argon (Ar); nitrogen fluoride (NF₃); tungsten fluoride (WF₆); or a fluorine-containing gas.
 4. The apparatus of claim 1, wherein the second gas comprises at least one of: ammonia (NH₃); amines; or hydrogen (H₂).
 5. The apparatus of claim 1, wherein the conical member comprises at least one of: aluminum; anodized aluminum; plasma electrolytic oxide (PEO) coated aluminum; alumina; aluminum nitride; silicon carbide; nickel; nickel plated aluminum; or nickel-plated stainless steel.
 6. The apparatus of claim 1, wherein the counter flow injector is sized to minimize recombination of radicals within the mixture of the first gas and the second gas.
 7. The apparatus of claim 1, wherein the counter flow injector comprises at least one of: nickel; nickel-plated stainless steel; anodized aluminum base material; PEO coated aluminum base material; ALD Al₂O₃ coated aluminum base material; aluminum oxide ceramic; aluminum nitride ceramic; or silicon carbide.
 8. A reaction system for forming a film, comprising: a plasma source, the plasma source generating a first gas; a conical member, the conical member configured to receive the first gas in a first direction; a counter flow injector, the counter flow injector introducing a second gas in a second direction, wherein the first direction is opposite to the second direction; an adjustable orifice plate mounted at the bottom of the conical member, the adjustable orifice plate defining an opening through which the plasma gas and the first fluid pass through; a reaction chamber that receives the first gas and the second gas, the reaction chamber comprising: a housing defining a plenum to receive the first gas and the second gas; and a showerhead with a plurality of holes for passing the first gas and the second gas onto a substrate to be processed; wherein the conical member promotes a mixing of the first gas and the second gas; and wherein adjusting a size of the opening of the adjustable orifice plate changes an extent of the mixing of the first gas and the second gas.
 9. The reaction system of claim 8, further comprising a plate having at least one radial arm, the plate being configured to enhance a spread of the second gas radially.
 10. The reaction system of claim 8, further comprising an injector gas source for generating the second gas.
 11. The reaction system of claim 8, wherein the plasma gas comprises at least one of: argon (Ar); nitrogen fluoride (NF₃); tungsten fluoride (WF₆); or a fluorine-containing gas.
 12. The reaction system of claim 8, wherein the first fluid comprises at least one of: ammonia (NH₃); amines; or hydrogen (H₂).
 13. The reaction system of claim 8, wherein the conical member comprises at least one of: aluminum; anodized aluminum; PEO coated aluminum; alumina; aluminum nitride; silicon carbide; nickel; nickel plated aluminum; or nickel-plated stainless steel.
 14. The reaction system of claim 8, wherein the counter flow injector is sized to minimize recombination of radicals within the mixture of the plasma gas and the first fluid.
 15. The reaction system of claim 8, wherein the counter flow injector comprises at least one of: nickel; nickel-plated stainless steel; anodized aluminum base material; PEO coated aluminum base material; ALD Al₂O₃ coated aluminum base material; aluminum oxide ceramic; aluminum nitride ceramic; or silicon carbide.
 16. The apparatus of claim 1, further comprising a plate within the conical member, the plate configured to spread the second gas radially.
 17. The apparatus of claim 1, wherein the plate is supported by radial arms.
 18. The apparatus of claim 1, further comprising a seal, wherein the first gas passes through the seal toward the bottom end.
 19. The apparatus of claim 1, wherein the a configurable orifice plate is between the conical member and a reaction chamber. 